Electric Apparatus

This application claims priority to Japanese Patent Application No. 2024-195844 filed on November 8, 2024. The entire content of the priority application is incorporated herein by reference.

The art herein relates to an electric apparatus.

Japanese Patent Application Publication Nos. 2016-139539 and 2016-139540 each describe an electric apparatus in which a motor and an inverter are housed in a single housing. The housing is divided to a first housing and a second housing, the motor is housed in the first housing, and the inverter is housed in the second housing. A terminal is located in the first housing, and a connector is located in the second housing. The terminal and the connector fit together when the second housing connects to the first housing.

In case a plurality of terminals is located in the first housing and the terminals contact their corresponding connectors simultaneously, a resistance force sharply changes during the connection of the second housing to the first housing. The disclosure herein provides a structure that mitigates a sharp change in a resistance force during connection of a second housing to a first housing.

An electric apparatus disclosed herein may comprise a first housing having an opening; a second housing configured to connect to the first housing and close the opening; a first terminal provided in the first housing, wherein the first terminal extends along an approaching direction in which the second housing approaches the first housing to connect to the first housing; a first connector provided in the second housing and connected to the first terminal; a second terminal provided in one of the first housing and the second housing, wherein the second terminal extends parallel to the first terminal; and a second connector provided in other of the first housing and the second housing, wherein the second connector is connected to the second terminal. A first stroke which is an inserted length of the first terminal in the first connector may be longer than a second stroke which is an inserted length of the second terminal in the second connector.

As the second housing approaches the first housing, the first terminal with the longer stroke contacts its corresponding connector (i.e., the first connector) before the second terminal contacts its corresponding connector. Then, after the first terminal has contacted the connector, the second terminal contacts its corresponding connector (i.e., the second connector). This sequential contact of the first and second terminals with their corresponding connectors mitigates a change in a resistance force during the connection of the second housing to the first housing.

Details of the art disclosed herein and further developments will be described in DETAILED DESCRIPTION.

10 Referring to the drawings, an electric apparatus according to an embodiment is described. The electric apparatus according to the embodiment is a motor unitin which an electric motor and an inverter are housed in a single housing.

1 FIG. 10 10 130 230 240 130 130 130 230 240 depicts a cross section of the motor unit. In the motor unit, an electric motor, an inverter, and a controllerare housed in a single housing. Hereinafter, the electric motoris simply referred to as the motor. In the drawings, configurations of the motor, the inverter, and the controllerare not depicted in detail.

100 200 100 101 200 100 101 200 100 109 The single housing is divided into a first housingand a second housing. The first housinghas an opening, and the second housingis configured to connect to the first housingand close the opening. The second housingis fixed to the first housingwith bolts.

130 100 100 10 130 The motoris housed in the first housing. A gear set (not depicted) is also housed in the first housing. The motor unitis a power unit mounted in an electric vehicle. The primary shaft of the motoris engaged with an input gear of the gear set, and an output gear of the gear set is engaged with an axle. In the drawings, some components related to the electric vehicle are not depicted.

230 240 200 240 130 230 230 130 240 The inverterand the controllerare housed in the second housing. The controllerdetermines a target output of the motorusing information from a sensor (described later) and controls the inverterbased on the target output. The invertergenerates AC electricity to drive the motorbased on commands from the controller.

140 130 140 130 130 140 240 111 210 210 211 211 111 111 210 111 211 140 240 140 240 111 210 210 111 A sensoris provided at the motor. The sensoris, for example, a resolver configured to detect a rotation angle of the rotor of the motoror an oil temperature sensor configured to measure a temperature of oil in the motor. The sensoris electrically connected to the controllervia a plurality of first terminalsand a first connector. The first connectorcomprises a plurality of first sockets, and the number of the first socketsis the same as the number of first terminals. The plurality of first terminalsis inserted in the first connectorand each of the first terminalsis in contact with corresponding one of the first sockets, so that the sensoris electrically connected to the controller. A sensor signal is transmitted from the sensorto the controllervia the first terminalsand the first connector. Electricity indicative of sensor data flows through the first connectorand the plurality of first terminals.

230 130 121 220 220 221 221 121 121 220 121 221 130 230 230 130 130 121 220 121 220 130 The inverterand the motorare electrically connected to each other via a plurality of second terminalsand a second connector. The second connectorcomprises a plurality of second sockets, and the number of the second socketsis the same as the number of the second terminals. The second terminalsare inserted in the second connectorand each of the second terminalsis in contact with corresponding one of the second sockets, so that the motorand the inverterare electrically connected to each other. The invertergenerates AC electricity to drive the motor, and the AC electricity is supplied to the motorthrough the plurality of second terminalsand the second connector. A large amount of electricity flows through the plurality of second terminalsand the second connectorto drive the motor.

111 210 121 220 The electricity flowing through the first terminalsand the first connectoris smaller than the electricity flowing through the second terminalsand the second connector.

111 110 110 100 110 100 121 120 120 130 111 121 100 111 121 100 The plurality of first terminalsis located on a first terminal block, and the first terminal blockis fixed to an inner wall of the first housing. In the drawings, the point of fixation between the first terminal blockand the first housingis not shown. The plurality of second terminalsis located on a second terminal block, and the second terminal blockis fixed to the motor. That is, the first terminalsand the second terminalsare fixed to the first housing. In other words, the first terminalsand the second terminalsare provided in the first housing.

210 240 220 230 210 220 200 210 220 200 The first connectoris fixed to the controller, and the second connectoris fixed to the inverter. That is, the first connectorand the second connectorare fixed to the second housing. In other words, the first connectorand the second connectorare provided in the second housing.

2 FIG. 2 FIG. 2 FIG. 1 FIG. 10 200 100 200 100 111 210 121 220 10 200 100 100 111 121 111 121 200 100 200 100 200 100 111 210 121 220 1 111 210 2 121 220 1 2 111 210 121 220 200 100 depicts a cross section of the motor unit, where the second housingis separated from the first housing. In the state where the second housingis separated from the first housing, the first terminalsare separated from the first connectorand the second terminalsare separated from the second connector. In a manufacturing process of the motor unit, the second housingis brought closer to the first housingin a direction of bold arrow X into connect to the first housing. The first terminalsand the second terminalsextend in the direction of bold arrow X in. In other words, the first terminalsand the second terminalsextend in an approaching direction of the second housingtoward the first housingfor connection of the second housingto the first housing. Thus, in the course of connection of the second housingto the first housing, the first terminalsconnect to the first connectorand the second terminalsconnect to the second connector. Here, a first stroke Lwhich is an inserted length of the first terminalsin the first connectoris longer than a second stroke Lwhich is an inserted length of the second terminalsin the second connector(the first stroke Land the second stroke Lare indicated in). This ensures that the first terminalscontact the first connectorbefore the second terminalscontact the second connectoras the second housingapproaches the first housing.

200 203 100 100 103 203 203 203 200 100 100 203 111 121 2 FIG. The second housingcomprises knock pinsfor alignment with the first housing, and the first housingcomprises knock holesconfigured to receive the knock pins. The knock pinsextends in the direction of bold arrow X in. In other words, the knock pinsextend in the approaching direction of the second housingtoward the first housingfor connection to the first housing. The knock pins, the first terminals, and the second terminalsextend parallel to each other.

3 203 103 1 111 210 3 203 103 111 210 200 100 200 100 203 103 111 210 121 220 3 1 2 1 FIG. A third stroke Lwhich is an inserted length of the knock pinsin the knock holesis longer than the first stroke L, which is the inserted length of the first terminalsin the first connector(the third stroke Lis indicated in). This means that the knock pinscontact the knock holesbefore the first terminalscontact the first connectoras the second housingapproaches the first housing. That is, in the course of connection of the second housingto the first housing, the knock pinsfirst contact the knock holes, then the first terminalscontact the first connector, and finally the second terminalscontact the second connector. This sequential order of contact is ensured by the relationship of L>L>L.

3 FIG. 203 103 200 100 203 103 111 210 121 220 depicts the state where the knock pinshave just contacted the knock holesas the second housingapproaches the first housing. The points of contact between the knock pinsand the knock holesare indicated with arrows A. In this state, the first terminalsare separated from the first connectorby a distance B, and the second terminalsare separated from the second connectorby a distance C.

200 100 203 103 200 100 111 210 As the second housingfurther approaches the first housing, the leading ends of the knock pinsare inserted into the knock holes, thereby aligning the second housingwith the first housing. Thereafter, the first terminalscontact the first connector.

4 FIG. 111 210 111 210 121 220 depicts the state where the leading ends of the first terminalshave just contacted the first connector. The point of contact between the first terminalsand the first connectoris indicated with an arrow D. In this state, the second terminalsare separated from the second connectorby a distance E.

200 100 111 210 121 220 As the second housingfurther approaches the first housing, the leading ends of the first terminalsare inserted into the first connector, and at the same time, the leading ends of the second terminalscontact the second connector.

5 FIG. 121 220 121 220 111 210 depicts the state where the leading ends of the second terminalshave just contacted the second connector. The point of connection between the second terminalsand the second connectoris indicated with an arrow F. In this state, the leading end portions of the first terminalsare already inserted in the first connector.

200 100 200 100 200 100 1 FIG. As the second housingfurther approaches the first housing, a flange of the second housingcontacts a flange of the first housing.depicts the state where the second housingis completely connected to the first housing.

200 100 203 103 111 210 121 220 203 111 121 As described above, in the course of the second housingapproaching the first housing, the knock pinsfirst contact the knock holes, then the first terminalscontact the first connector, and finally the second terminalscontact the second connector. This sequential order of contact is ensured by the relationship of L3>L1>L2. Advantages of the sequential contact of the knock pins, the first terminals, and the second terminalsare described below.

203 103 111 121 200 100 111 121 111 210 121 220 The leading ends of the knock pinsare inserted into the knock holesbefore the first terminalsand the second terminalscontact the connectors. That is, the second housingis aligned with the first housingbefore the first terminalsand the second terminalscontact the connectors. This allows for secure insertion of the first terminalsinto the first connectorand secure insertion of the second terminalsinto the second connector.

111 121 200 100 1 2 111 121 200 100 1 2 Once the first terminalsand the second terminalssequentially start to contact the connectors, a resistance force gradually increases as the second housingapproaches the first housing. If the first stroke Lwere equal to the second stroke L, the first terminalsand the second terminalswould simultaneously contact their corresponding connectors. This may lead to a sharp change in the resistance force in the second housingapproaching the first housing. The difference between the first stroke Land the second stroke Lmitigates such a sharp change in the resistance force.

111 121 111 121 111 210 121 220 111 210 121 220 200 100 111 121 220 111 210 111 210 121 Electricity flowing through the first terminalsis smaller than electricity flowing through the second terminals, and thus the first terminalsmay be thinner and weaker than the second terminals. A resistance force in inserting the first terminalsinto the first connectoris lower than a resistance force in inserting the second terminalsinto the second connector. This feature is also advantageous. The insertion of the first terminalsinto the first connectorstarts before the insertion of the second terminalsinto the second connector. In this case, even a slight change in the resistance force occurring while the second housingis approaching the first housingmay be attributed to improper insertion of the first terminals. If the second terminalswith a larger resistance force upon insertion contacted the second connectorbefore the first terminalscontact the first connector, a slight change in the resistance force between the first terminalsand the first connectorcould not be detected since the resistance force of the second terminalsis large. Thus, contacting the terminals with a smaller resistance force with the connector first improves detection sensitivity for improper insertion.

6 FIG. 120 130 120 123 130 124 123 124 120 130 123 203 203 123 103 124 110 100 203 103 In, the second terminal blockis depicted as being separated from the motor. The second terminal blockcomprises knock pins, and the motorcomprises knock holes. The knock pinsand the knock holesalign the second terminal blockwith the motor. The knock pinsand the knock pinsextend parallel to each other. The knock pinsand the knock pinsmay have the same size, and the knock holesand the knock holesmay have the same size. This improves efficiency for forming of the knock pins and the knock holes. Knock pins (and knock holes) for aligning the first terminal blockwith the first housingmay have the same size as the size of the knock pins(and the knock holes), although this is not depicted.

2 FIG. 200 100 100 203 200 100 200 100 100 203 200 100 Some of points to be noted regarding the art described in the embodiment will be listed. The bold arrow X inindicates the “approaching direction of the second housingtoward the first housingfor connection to the first housing”. The knock pinsfor alignment of the second housingwith the first housingextend along the bold arrow X. That is, the “approaching direction of the second housingtoward the first housingfor connection to the first housing” may be expressed in other words as “an extending direction of the knock pinsfor alignment of the second housingwith the first housing”.

1 111 210 111 2 121 220 121 3 203 103 203 The first stroke Lrefers to the length of portions of the first terminalsthat are inserted in the first connectorout of the overall length of the first terminals. The second stroke Lrefers to the length of portions of the second terminalsthat are inserted in the second connectorout of the overall length of the second terminals. The third stroke Lrefers to the length of portions of the knock pinsthat are inserted in the knock holesout of the overall length of the knock pins.

10 100 200 203 103 203 203 3 1 In the motor unit, one of the first housingand the second housingmay comprise the knock pinsfor alignment, and the other thereof may comprise the knock holesinto which the knock pinsare inserted. The stroke of the knock pins(i.e., the third stroke L) may be longer than the first stroke L.

111 210 111 210 111 210 111 210 111 210 111 210 121 220 The “resistance force in inserting the first terminalsinto the first connector” refers to a force generated between the first terminalsand the first connectorin inserting the first terminalsinto the first connector, wherein this force is generated in the opposite direction to the insertion direction. In other words, the “resistance force in inserting the first terminalsinto the first connector” is a frictional force generated between the first terminalsand the first connectorin inserting the first terminalsinto the first connector. The same applies to the “resistance force in inserting the second terminalsinto the second connector”.

100 200 100 200 200 100 111 121 210 220 The terms “first housing” and “second housing” are used for convenience purposes to distinguish two housings divided from the single housing. The first housing(the second housing) is interchangeable with the second housing(the first housing). Similarly, the term “first terminals” is interchangeable with the term “second terminals”, and the term “first connector” is interchangeable with the term “second connector”.

10 111 210 121 220 101 100 203 200 100 101 In the motor unit, the first terminalsmay be connected to the first connectorand the second terminalsmay be connected to the second connectorthrough the openingof the first housing. The knock pinsfor alignment of the second housingwith the first housingextend perpendicular to a surface (opening surface) of the opening.

10 111 121 100 210 220 200 111 220 100 121 210 200 121 100 200 220 100 200 121 100 200 220 100 200 In the motor unitaccording to the embodiment, the first terminalsand the second terminalsare fixed to the first housing, and the first connectorand the second connectorare fixed to the second housing. Instead of this, the first terminalsand the second connectormay be fixed to the first housing, and the second terminalsand the first connectormay be fixed to the second housing. That is, the second terminalsmay be fixed to one of the first housingand the second housing, and the second connectormay be fixed to the other of the first housingand the second housing. In other words, the second terminalsmay be provided in one of the first housingand the second housing, and the second connectormay be provided in the other of the first housingand the second housing.

10 130 230 240 10 100 200 130 100 230 130 240 230 200 130 200 230 240 100 130 100 200 230 240 111 210 140 130 240 121 220 130 230 The electric apparatus according to the embodiment is the motor unitcomprising the motor, the inverter, and the controller. The housing of the motor unitis divided into the first housingand the second housing. The electric motoris housed in the first housing, and the inverterconfigured to drive the electric motorand the controllerconfigured to control the inverterare housed in the second housing. Instead of this, the electric motormay be housed in the second housing, and the inverterand the controllermay be housed in the first housing. That is, the electric motormay be housed in one of the first housingand the second housing, and the inverterand the controllermay be housed in the other thereof. The first terminalsand the first connectorconnect the sensorassociated with the electric motorto the controller. The second terminalsand the second connectorconnect the electric motorto the inverter.

10 The technology disclosed herein is not limited to the motor unit. The technology disclosed herein is applicable to any structures comprising electric devices and a dividable housing that houses the electric devices. The first housing may be referred to as “a housing body having an opening”, and the second housing may be referred to as “a housing cover for closing the opening”. The first terminals and the first connector as well as the second terminals and the second connector electrically connect electric device(s) in the first housing to electric device(s) in the second housing.

While specific examples of the present disclosure have been described above in detail, these examples are merely illustrative and place no limitation on the scope of the patent claims. The technology described in the patent claims also encompasses various changes and modifications to the specific examples described above. The technical elements explained in the present description or drawings provide technical utility either independently or through various combinations. The present disclosure is not limited to the combinations described at the time the claims are filed. Further, the purpose of the examples illustrated by the present description or drawings is to satisfy multiple objectives simultaneously, and satisfying any one of those objectives gives technical utility to the present disclosure.